3D Printed Drill: Difference between revisions
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=Vision= | =Vision= | ||
The USA alone throws away at least 2M broken cordless drills per year (see market research below, and develop the market research further by contacting sources). A lifetime design, modular, 3D Printed cordless drill is a perfect solution here, and builds upon the current 3D printing craze.''' | The USA alone throws away at least 2M broken cordless drills per year (see market research below, and develop the market research further by contacting sources). A lifetime design, modular, 3D Printed cordless drill is a perfect solution here, and builds upon the current 3D printing craze.''' | ||
'''Problem statement''' - drills, and especially cordless drills, are throwaway devices. They break and you can't fix them readily because they are not appropriate technology. Here we design the world's first appropriate technology cordless drill. | |||
The goal is to select an appropriate [[Depth of Modularity]] to make any cordless drill motor, battery, speed trigger, gear set, and Chuck inter-operable with any other. | |||
This converts any drill to one about 10-100 times cheaper (lifetime extends from 1 to 100 years, and cost drops from 100 to about 50 for a professional grade drill - for the initial purchase, so all things considered, the open source version is about 100x cheaper over the lifetime. | |||
=Requirements= | =Requirements= | ||
| Line 7: | Line 13: | ||
:*battery interface to connect to any existing battery pack | :*battery interface to connect to any existing battery pack | ||
:*battery pack | :*battery pack | ||
*Modular Architecture | *Modular Architecture | ||
*Motor, Gearbox, Chuck, Battery pack, Charger, and Trigger | *Motor, Gearbox, Chuck, Battery pack, Charger, and Trigger can be sourced off-the-shelf | ||
*Initial is clutchless, later phase includes clutch | *Initial is clutchless, later phase includes clutch | ||
*Professional grade - 18V or higher | *Professional grade - 18V or higher | ||
*Based on a | *Based on a 3D printed pack for [[18650 Cells]]. | ||
==Hacking Requirements== | ==Hacking Requirements== | ||
* | *After-opensource-market battery adapters - allow any battery from any other drill to be used. | ||
==Later Phase Requirements== | ==Later Phase Requirements== | ||
*Open source drill motor, and gear box, etc | *Open source drill motor, and gear box, etc | ||
*Battery pack is modular, and battery build is modular - made of common available cells + electronic, instead of monolithic. | *Battery pack is modular, and battery build is modular - made of common available cells + electronic, instead of monolithic. | ||
Revision as of 21:05, 3 January 2019
Vision
The USA alone throws away at least 2M broken cordless drills per year (see market research below, and develop the market research further by contacting sources). A lifetime design, modular, 3D Printed cordless drill is a perfect solution here, and builds upon the current 3D printing craze.
Problem statement - drills, and especially cordless drills, are throwaway devices. They break and you can't fix them readily because they are not appropriate technology. Here we design the world's first appropriate technology cordless drill.
The goal is to select an appropriate Depth of Modularity to make any cordless drill motor, battery, speed trigger, gear set, and Chuck inter-operable with any other.
This converts any drill to one about 10-100 times cheaper (lifetime extends from 1 to 100 years, and cost drops from 100 to about 50 for a professional grade drill - for the initial purchase, so all things considered, the open source version is about 100x cheaper over the lifetime.
Requirements
- Made of 3 main modules:
- body
- battery interface to connect to any existing battery pack
- battery pack
- Modular Architecture
- Motor, Gearbox, Chuck, Battery pack, Charger, and Trigger can be sourced off-the-shelf
- Initial is clutchless, later phase includes clutch
- Professional grade - 18V or higher
- Based on a 3D printed pack for 18650 Cells.
Hacking Requirements
- After-opensource-market battery adapters - allow any battery from any other drill to be used.
Later Phase Requirements
- Open source drill motor, and gear box, etc
- Battery pack is modular, and battery build is modular - made of common available cells + electronic, instead of monolithic.
- Modular gearbox means any amount of torque can be generated.
- Different toolheads, including hydraulic high pressure pump for dump trailers, jacks, etc.
- Battery pack is stackable - 18 or 36v battery if one or two modules are used
BOM and Parts Extraction
- 57 geardown 18v motor - [1]
- 735 motor - 18V, 5/44 mm - [2]
- 755 motor - 24V, 5mm shaft, 42mm wide - [3]
- 775 motor - 12-36V- 5/42 - [4]
- 775, 795, 895 - the larger one has lower RPM (12000, 10000, 6000 rpm) - larger has more solid connectors - [5]
- RS555 - 12-36V - 2000-6000 RPM - but 3 mm or smaller shaft. This appears to work - [6] - but appears to be too fast.
- 3D printed battery holders - [7]
- extracting a gear motor from a drill - [8]
- Making a hub for a cordless drill - [9]
- Good video of extraction for a robot. There are standard motor sizes that can be used. Clutch consists of ball bearings that are pressed down with a spring which catch on a motor disk. [10]
- 3D Printed Gears - [11]
- Standard Motors - 550 size motor.
- Standard gearboxes - Dewalt example - [12][13]
- Standard chucks
Market Research
- Market share report - [14]
- Harbor Freight recalls 1.7M cordless Drill Master drills -[15]
- The two above imply that there is at least 10M cordless drills sold in the USA every year, assuming the 1M is all that Harbor Freight sold (gross underestimate). That is about a $1B market in the USA alone, or 6B globally.
Lifetime of a Cordless Drill
- 1-2 years in a contractor scenario, check out the guy who spends $5k/year on drill replacements for 40 cordless drills/saws - [16]
- 4 years, woodworking business - [17]
Links to 3D Printed Cordless Drills
- Small one - [18]
- Stratasys - [19]
- Taking a DC motor out of a cordless drill -@[20]
- Alibaba cordless drill motors - [21]